Intumescent weatherseal

ABSTRACT

A weatherseal adapted to be installed in a door or window opening includes a spine, a resilient foam core, an intumescent material, and a liner. The spine has first and second ends, the first end adapted for mounting the weatherseal to the door or window opening. The resilient foam core is attached to the spine, proximate the second end of the spine. The intumescent material is arranged proximate the foam core. The liner encloses the flexible foam core and the intumescent material. The weatherseal or a portion may be color-coded to identify the weatherseal for fire rated applications.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. provisionalpatent application Ser. No. 61/228,713, filed Jul. 27, 2009, thedisclosure of which is being incorporated herein by reference in itsentirety.

FIELD OF THE INVENTION

The present invention relates to weatherseals. More particularly, thepresent invention relates to weatherseals that include an intumescentmaterial.

BACKGROUND OF THE INVENTION

Foam weatherseals (weather stripping) are well known in the art as a wayof preventing water, air and/or other unwanted contaminants from seepingpast a closed door, window, or the like. More specifically, aweatherseal is generally applied to a door jamb or window frame forcontact with the respective door or window when closed. A typicalweatherseal can have a complex geometric profile and is typicallymanufactured in continuous or cut lengths to provide a seal between thedoor or window and associated jamb. Conventional weatherseals typicallyconsist of a foam profile attached to a rubber or plastic extrusion andare usually attached to a door or window frame by inserting a portion ofthe extrusion into a door or window kerf. Alternatively, the weathersealmay be attached to a door jamb, window frame or other component usingadhesive tape, fasteners, or the like.

Conventional weatherseals, while being effective at preventing thepassage of water and other contaminants, are generally not effective atslowing spread of a fire and/or smoke around the closed door or window.

Intumescent materials are known to help retard the spread of fires.Specifically, intumescent materials swell when exposed to the elevatedtemperatures caused by a fire. When swollen, the materials are poorconductors of heat, and thus slow the spread of the fire. Intumescentsmay also include hydrates, that release water vapor at elevatedtemperatures, to also slow the spread of the fire.

Some known applications incorporate intumescent materials andweatherseals. For example, U.S. Pat. No. 4,676,025 shows a remotelyactivatable seal that incorporates an intumescent bead of material thatis activated by a heat source (i.e., coiled high resistance wire)disposed in the intumescent material. However, there are a variety ofpotential problems for such a seal, since the high resistance wire mustbe activated by some alarm condition, requiring a control system, aswell as a reliable power source. It is contemplated that the electricalcurrent and power required to activate initially and fully theintumescent material may not be available in an emergency. Moreover,there may be a reliability concern. Repeated opening and closing of thedoor, window, etc. being sealed and resultant flexing of the embeddedhigh resistance wire and associated external wiring may compromise thewiring or cause an open circuit condition, making the remote, earlyactivation of the intumescent portion of the seal ineffective. Theintumescent bead is also encased fully within the resilient cellularfoam core. Accordingly, when installed in a door frame or other opening,the intumescent bead of the weatherseal does not have direct contactagainst the door jamb or frame. Accordingly, when activated, theintumescent material could expand unevenly, in a relatively uncontrolledmanner, creating gaps around the door slab. Flame and smoke could breachthe door slab and frame, rendering the seal unsatisfactory for itsintended purpose.

Moreover, this prior art seal would be relatively expensive tomanufacture and install, since it requires the inclusion of the highresistance wire coil within the seals and interconnecting the coils withexternal wiring and a control/power supply external to the seals.

There is a need in the art for an easily and inexpensively manufacturedweatherseal that is capable of sealing a door, window, or the likeduring normal, i.e., non-fire, operating conditions, but that alsoretards the spread of a fire beyond the closure. Further, there is aneed in the art to be able to install such weatherseals in a mannerconsistent with non-intumescent seals, without the need to electricallyinterconnect the seals to each other or to an external control/powersupply.

SUMMARY OF THE INVENTION

The present invention addresses the foregoing needs in the art byproviding an improved intumescent weatherseal and a method of makingsuch a seal.

According to one aspect of the invention, a weatherseal adapted to beinstalled in a door or window includes in one embodiment a spine, aresilient foam core, an intumescent material, and a liner. The spine hasfirst and second ends, the first end adapted for mounting theweatherseal to the door or window opening. The resilient foam core isattached to the spine, proximate the second end of the spine. Theintumescent material is arranged proximate the foam core. The linerencloses the flexible foam core and the intumescent material.

In one embodiment, an intumescent weatherseal adapted to be installed ina door or window opening includes a spine having first and second ends,the first end adapted for mounting the weatherseal in the opening with aresilient foam core attached to the spine, proximate the second end ofthe spine. An intumescent material is arranged proximate an edge of theweatherseal, adapted to abut structure when installed in the opening. Aliner encloses the resilient foam core and the intumescent material. Theresilient foam core, the intumescent material, and the liner can beconfigured to form a substantially V-shaped flexible seal, with asupport leg proximate the spine and a sealing leg depending angularlyfrom the support leg. The intumescent material is disposed in at leastone of the support leg and the sealing leg. In one embodiment, theintumescent material is formed in the support leg and extends along aside of the support leg disposed outside the V-shape. The foam core canbe either an open cell foam or a closed cell foam, for example polyetherurethane. In various embodiments, one or more flexible fins can dependfrom the spine. Alternatively or additionally, the liner can include aweakened portion proximate the intumescent material, such as a series ofperforations, a material having a melting point substantially at or lessthan an activation temperature of the intumescent material, or be madeof a more flexible material.

In another embodiment, an intumescent weatherseal adapted to beinstalled in a door or window opening includes an intumescent materialarranged proximate an edge of the weatherseal, adapted to abut structurewhen installed in the opening. A sealing material can be arrangedproximate the intumescent material, and structure is provided forattaching the weatherseal in the opening. At least a portion of theweatherseal, such as, but not limited to, an exposed portion of thespine, may include coloring coding. The color coding may include, orconsist essentially of, a red coloring.

In another aspect, the present invention provides a method of forming aweatherseal. The method includes, in one embodiment, providing a liner,pouring a reacting foam mass onto a side of the liner, and inserting theliner with foam mass thereon into a mold. Concurrent with inserting theliner into the mold, a spine is inserted into the mold and anintumescent material is inserted into the mold. The method also includesmaintaining the liner with the foam mass thereon, the spine, and theintumescent material in the mold for a time sufficient for the reactingfoam mass to expand. The expansion of the foam can be constrained by themold to shape the weatherseal. Optionally, the method includes supplyingan adhesive to the liner to aid in bonding the liner with at least oneof the spine, the foam mass, and the intumescent strip. In variousembodiments, the method can produce a weatherseal that is substantiallyV-shaped. The foam mass can include an adhesive that binds at least oneof the liner, the spine, and the intumescent material thereto. Themethod can also include a curing step, of curing the reacting foam massto stop expansion of the reacting foam mass.

These and other aspects, objects, and features of the invention may beappreciated with reference to the accompanied detailed description ofthe invention and figures, which describe and illustrate preferredembodiments of the present invention.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

FIG. 1A is a cross-section of a weatherseal having an intumescentmaterial arranged proximate a spine of the weatherseal, according to afirst embodiment of the present invention;

FIG. 1B is a cross-section of a weatherseal having an intumescentmaterial forming part of a foam sealing leg of the weatherseal,according to another embodiment of the present invention;

FIG. 2 is a perspective view of the weatherseal illustrated in FIG. 1A;

FIG. 3 is a perspective view of a weatherseal according to anotherembodiment of the invention;

FIG. 4A is a perspective view of a weatherseal according to anotherembodiment of the invention;

FIG. 4B is a side view of a weatherseal having an intumescent materialextending along at least a section of the base portion according toanother embodiment of the invention;

FIG. 4C is a side view of the weatherseal of FIG. 4B with a base portionhaving an angled section;

FIG. 5A is a perspective view of a weatherseal according to anotherembodiment of the invention;

FIG. 5B is a different perspective view of the weatherseal illustratedin FIG. 5A;

FIG. 6 is a perspective view of a weatherseal according to anotherembodiment of the invention; and

FIG. 7 is a block diagram of a process for forming a compositeweatherseal, in accordance with one embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1A, 1B, and 2 illustrate a weatherseal 10 in accordance with oneembodiment of this invention. The weatherseal includes a spine 12 havinga plurality of flexible fins 14 extending from one end thereof forengaging a kerf cut in a door or window frame. The spine 12 is generallystraight or L-shaped and has a base portion 16 from which the flexiblefins 14 extend and a foot 18 extending at approximately a right anglefrom the base portion 16 for supporting the remainder of the door seal10. The spine 12 can be made from extruded molded plastic, such aspolypropylene, and is semi-rigid. The spine 12 can be sufficiently stiffto support the door seal but flexible enough to allow it to be insertedinto a kerf in a door frame and to accommodate manufacturingimperfections and geometric variability in the width and depth of thekerf. The fins 14 can be the same material as the spine 12 or preferablycan be made of polypropylene and can be more flexible than the spine 12.The fins 14 are sufficiently flexible to retain the spine 12 in thekerf. To this end, the fins 14 and the spine 12 may be formed ofdifferent materials, or from different types of the same material, e.g.,polypropylene.

The spine 12 and fins 14 are not necessarily made of polypropylene,however. They could be made of any thermoplastic. Such materials may beextruded or otherwise molded, and could include PVC, polyethylene,nylon, urethane, polyester, polycarbonate, or any combination of thesematerials. The spine 12 (and fins 14) can be formed as a continuouslength, by extrusion or coextrusion, for example. In one embodiment, thespine 12 (and fins 14), or portions thereof, may have a colorconcentrate (e.g., “red” coloring polymer) added thereto during theformation process. Alternatively, a colored coating may be added tospine 12 (and fins 14), or portions thereof, after formation. Providinga red coloring, or other color coding, to at least the exposed portionof the spine 12 or any other portion or the entirety of the weathersealis advantageous, for example, in providing an identifying mark to apurchaser or an installer of the weatherseal to identify the weathersealas having fire retarding properties.

A foam core or profile 20 is attached to the foot 18 of the spine 12. Inthis embodiment, the foam core 20 has a generally V-shaped configurationand includes a support leg 22 enveloping the foot of the spine and asealing leg 24 adapted to engage the moving portion of a door or windowwhen the seal is used. The foam profile 20 can be formed from open orclosed cell foam, such as polyether urethane. In one embodiment, thefoam is a high resiliency TDI-based polyether urethane foam. Alternativefoam compositions include MDI/TDI blends, polyester/polyether blends orEVAs. Of course, the invention is not limited to this foam. Other foamsinclude thermoplastic polyolefins, thermoplastic vulcanizates, strenicthermoplastic elastomers, PVC compounds, and combinations and subclassesof such foams. Alternatively, the foam core 20 could be formed from analternative material such as foamed rubber, including but not limited toone or more of silicone, neoprene, nitrile, SBR, and EPDM. The foam corematerial can generally be chosen based on the manufacturing process anddesired characteristics for the part, such as density, durometer,compression set, cost, etc.

An intumescent material 26 can be arranged proximate the foam core 20 inone embodiment, forming a portion of the V-shaped profile, as shown inFIG. 1A. The intumescent material 26 can be provided as a strip andforms, along with a portion of the foam core 20, a portion of thesupport leg 22 of the V-shaped profile. In this embodiment, theintumescent material is arranged at an outer surface (relative to theV-shape) of the support leg 24. In this manner, the intumescent materialis disposed proximate the window or door frame in which the kerf isformed. Of course, there will, in certain embodiments, be liner andpotentially spine disposed between the intumescent material and thestructure when installed. In another embodiment, the intumescentmaterial 26 could form part or all of the sealing leg 24, as shown inFIG. 1B. In that embodiment, the intumescent material 26 could bearranged closer to the window sash or door. In other alternativeembodiments, the intumescent material 26 could be disposed in both thesealing and support legs 24, 22. By positioning the intumescent material26 against an optional seal liner 28 and, accordingly, in the clearancegap against the structure being sealed (e.g., such as the door jamb,frame, or door slab, instead of in some other portion of the seal), evenintumescent action all around the door jamb and door slab is ensured.Accordingly, even if a portion of the weatherseal were to fail, due toexposure to elevated temperatures or flames, the location of theintumescent material 26, in the clearance gap between the door frame andthe door slab (e.g., surrounded by fenestration structure on three sidesor at least two parallel spaced sides), ensures an optimal protectivescheme. This is typically a better configuration than, for example,providing the intumescent material 26 in an area such as an insidecorner, bounded by fenestration structure on only two adjacent sides.

The intumescent material may be an exfoliating graphite-based material,such as that described in U.S. Pat. No. 6,207,085 the disclosure ofwhich is incorporated herein by reference in its entirety. This type ofmaterial is fully air and water stable, which is useful in sealingapplications, where the seal is likely to be exposed to such elements.One embodiment of the invention includes a Thermaflex 2 mm graphiteintumescent seal provided by Firewise Supplies, Ltd, of Cambridge, UK.Other possible graphite-based intumescent seals include, for example,graphite impregnated paper-type seals provided by Intumescent SystemsLtd of Dover, UK, under the tradename Envirograf®. Any suitable graphiteor glass filled intumescent material or the like may be used.

However, other intumescent materials can be used that are not air andwater stable. In such embodiments, the intumescent material may becovered to shield the material from the elements. For example, aprotective coating, such as the liner 28 described below, may shield theintumescent material from the elements. In another embodiment, theintumescent material could be embedded in the foam core, such that thefoam core acts to shield the intumescent material. A relatively smallamount of intumescent material can plug a much larger gap. For example,in one embodiment, the intumescent material strip can have a rectangularcross-section on the order of about 2 mm by 10 mm and exhibit anexpansion ratio of greater than about 20:1 or of greater than about30:1, such as about 37:1. By using a pre-formed, cured intumescent stripof material, there is no need to accommodate any drying or curing of theintumescent material, that might otherwise be required to manufacturethe weatherseal, as discussed in more detail below. Further, theplacement and cross-sectional size and extent of the intumescentmaterial in the weatherseal can be readily controlled.

In one embodiment the intumescent material may include, or consistessentially of, ammonium phosphate or sodium silicate. In alternativeembodiments, other forms of intumescent materials may be used including,but not limited to, intumescent putty or caulks that can be pumped ordispensed in the appropriate location into the part during manufacture.Note, however, that certain silicate type and other types of intumescentmaterials provided in putty or caulk form can contain oils or solventsthat are not necessarily compatible with the other materials typicallyused in weatherseals. Additionally, in such embodiments, appropriatecuring of the putty or caulks in the finished weatherseal should beconsidered. For example, a fully encapsulating liner and/or closed cellfoam profile can inhibited the oils and solvents from evaporating,thereby preventing curing of the intumescent material within areasonable time frame. In these alternative embodiments, some form ofinternal venting in the weatherseal can be provided, so that theintumescent material need not be provided in strip form.

In another embodiment, the foam body 20 and the intumescent material 26are surrounded by the liner 28 having two edges 30 a, 30 b attached toupper and lower surfaces of the base portion 16 of the spine 12 by anadhesive, ultrasonic welding or some other suitable attachmenttechnique. The liner 28 can be made from a film material formed frompolyethylene or the like that can be directly bonded to the surface ofthe spine 12. Other liner materials include any flexible film including,but not limited to, PVC, polyurethane, polyester, polypropylene, EVAs,polyimides, coated fabrics and laminated structures of films, films andfabrics, and films and metal foils. Alternatively, the liner 28 could beformed from a liquid coating, as described, for example, in U.S. Pat.No. 5,192,586, the disclosure of which is herein incorporated byreference in its entirety.

As illustrated in FIG. 1, the liner 28 in this embodiment contacts boththe intumescent strip 26 and the foam core 20. However, the intumescentstrip 26 may alternatively only contact the foam material, for example,if the intumescent strip 26 is completely embedded in the foam core 20.

In use, the spine 12 is inserted into a kerf in the frame of the closureto be sealed, and the support leg 22 of the seal 10 contacts the frame.In the illustrated embodiment, the intumescent strip 26 is thus arrangednext to the frame of the closure. The sealing leg 24 extends from thesupport leg 22 such that when the closure is closed, the closurecontacts the sealing leg 24 and biases the sealing leg 24 toward (andtypically into contact with) the support leg 22. The combination of thesupport and sealing legs 22, 24 seals any gap between the frame andclosure to preclude passage of contaminants therethrough. When excessiveheat is introduced, i.e., heat resulting from a fire and exceedingactivation temperature of the intumescent, the intumescent stripresponds by expanding, further filling and sealing the gap, therebyslowing the spread of the fire and smoke past the closure.

The liner 28 covering the intumescent material 26 can be designedadvantageously so as not to preclude expansion of the intumescentmaterial 26. For example, the liner 28 can includes a weakened portionproximate the intumescent material 26. This weakened portion may havesufficient flexibility that it stretches as the intumescent material 26expands. Alternatively, the weakened portion may have a melting pointapproximately the same as or lower than the temperature needed toactivate the intumescent. In this arrangement, the liner 28 melts, so asto not inhibit expansion of the intumescent material 26. Of course, thecomposition of the weakened portion may be the same as the compositionof the entirety of the liner 28.

In another embodiment, illustrated in FIG. 3, the weakened portion ofthe liner is an area including a series of perforations 32. In the eventof a fire, the liner tears at the perforation 32 in response to pressurefrom the expanding intumescent material. Alternatively, the weakenedportion could include a thinner layer that would easily tear underinternal pressure. Other structures for the weakened portion of theliner will be apparent based on the foregoing description.

According to one method of forming the weatherseal 10 with intumescentmaterial, a continuous, flat length of the liner is conveyed along aconveyance direction. A reacting foam mass is poured onto the liner andthe liner with foam mass thereon is guided into a moving mold. Thespine, provided as a continuous length, and the intumescent strip, alsoprovided as a continuous length, are guided into the moving moldconcurrently and independently of each other and the liner, also alongthe conveyance direction. The moving mold wraps the liner around thefoam mass, intumescent strip, and insert. Once properly formed, the endsof the liner are affixed to the insert. The reacting foam mass expandsto form the V-shape described above. The reacting foam mass may includean adhesive property that acts to bond the liner, insert and intumescentstrip together, resulting in the seal described above. Alternatively, orin addition, portions of the inner surface of the liner may be coatedwith an adhesive to aid in forming the seal. As the completed sealemerges from the moving mold, it may be cut to length using knownmethods. Accordingly, this method of manufacture is a continuousprocess, utilizing a continuous mold cap and a continuous mold base, forexample of the endless belt variety known to those skilled in the art.The foaming mixture is poured onto the liner in a liquid state, with theinsert, liner and intumescent material all being brought together,folded, and constrained within the mold base and cap, while the foammixture expands and sets. After emerging from the belt mold and beingcoiled or cut to length, the weatherseal 10 can optionally be introducedinto a oven at elevated temperature for curing.

An example composite weatherseal formation process 700 is shown in FIG.7. As described above, the process may, for example, be a continualmolding process combining a foam core with a harder spine or footsection all sheathed with a low friction polyethylene exterior liner.The continual molding process can use folder tooling to position andguide all components together, prior to feeding into a profiled moldsection. In addition, the required tooling may include a guide to insertone or more strips of intumescent material in the appropriate locationand orientation, which is held in place by the expanded polyurethanefoam core.

In one embodiment, the process involves providing a liner 710 and, inone embodiment, supplying an adhesive 720 to the liner to aid in bondingthe liner with at least one of the spine, the foam mass, and theintumescent strip. In an alternative embodiment, no adhesive isrequired, or the foam mass includes an adhesive that binds at least oneof the liner, the spine, and the intumescent material thereto. Theprocess next involves mixing and dispensing a reacting foam mass on tothe liner 730 and sequentially or concurrently inserting the liner withfoam mass thereon into a mold 740, inserting the spine into the mold750, and inserting the intumescent material into the mold 760. Theliner, spine, and intumescent material are then held in the mold 770 fora time sufficient for the reacting foam mass to expand, with theexpansion of the foam constrained by the mold to shape the weatherseal.In one embodiment, the resulting weatherseal is substantially V-shaped,although any appropriate shape of weatherseal may be produced by themethods described herein. The process may, in one embodiment, alsoinclude curing the reacting foam mass 780 to stop expansion of thereacting foam mass.

The quantity of intumescent contained in the resulting seal may, forexample, be the amount needed for 30 minute fire rated doors. Such doorsare normally in PVC carriers that carry a fire loading and are resistiveto intumescent expansion. As a result, the intumescent seals describedherein will, in certain embodiments, perform better than similarstandard seals in such non-intumescently expanding doors.

In addition, the processes described herein allow for the insertion ofcommercially available intumescent strip into the foam core of astandard cold smoke seal to produce a combined cold smokeseal/intumescent seal. This provides an advantage over prior art firedoors by allowing a single seal to provide the functionality of twoprior art seals to produce a high quality smoke/weatherseal with a hotseal.

In another embodiment, fabrication could be achieved using a dieprocess. Specifically, a shaped die can be provided through which theliner, insert, foam and intumescent strip are pulled. In thisembodiment, a side of the liner proximate the insert, foam and strip canbe coated with an adhesive that maintains the sealing profile in theshape formed by the die, similar to what is described in the '586 patentreferenced above.

The geometry of the weatherseal depends upon the application, andweatherseals according to the invention can be made of sizes requiredfor any application. That is, weatherseals according to the inventioncan be fabricated in many sizes and shapes, for use in connection withmany different closures. For example, FIGS. 4A-4C illustrates anotherseal 110 similar to the weatherseal 10 illustrated in FIGS. 1-3, butthat does not include the spine or flexible fins. In FIG. 4A, theweatherseal 110 has a foam core 120 that is generally V-shaped, having asealing leg 122 and a support leg 124. The intumescent material 126 isdisposed in the support leg 124, and a liner 128 is formed about thefoam core 120 and intumescent material 126. The weatherseal 110functions similar to the weatherseal 10, described above, but is appliedin a slightly different manner. Specifically, instead of including aspine and flexible fins that are inserted into a kerf, the seal includesan adhesive strip 134, applied to the support leg 122. The adhesivestrip 134 can include a backing strip that is removed to expose anadhesive used to attach the weatherseal to a frame.

The weatherseal 110 shown in FIG. 4A can be made in substantially thesame manner as the weatherseal 10, although without the need tointroduce the spine into the mold. The adhesive strip 134 can be appliedusing known methods. In the illustrated embodiment, the adhesive strip134 is applied after the liner 128 is wrapped around the foam core 120and intumescent material 126, and is formed over a seam created atoverlapping edges of the liner 128. Alternatively, the adhesive strip134 could be applied to the liner prior to formation of the seal. Inthis embodiment, the adhesive strip 134 can be precisely placed, toensure its position on the support leg 126 when the foam cures.

FIGS. 4B and 4C shown another weatherseal 150 having a spine 155 with aflexible fin 160 extending from one end thereof for engaging a kerf 162cut in a door or window frame. The spine 155 includes a base portion 165from which the flexible fin 160 extends, with an intumescent material170 extending along at least a section of the base portion 165. Asealing leg 175 extends from the end of the base portion to engage themoving portion of a door or window when the seal is used. The sealingleg 175 may engage structures of any appropriate distance from the baseportion 165 within a range defined between a minimum and maximumdistance. In an alternative embodiment, the sealing leg 175 holdsintumescent material in addition to, or in place of, the base portion165. In a further alternative embodiment, a plurality of flexible fins160 may extend from the base portion 165, as described herein. In theembodiment of FIG. 4C, the base portion 165 includes an angled section180.

Although the embodiments described above include a foam core, theinvention is not limited to foam-based products. Extruded weathersealsalso can be formed using the invention. For example, FIGS. 5A and 5Bshow different perspectives of an extruded weatherseal 210 with a hollowbulb 240 and a secondary sealing flap 250. In the illustratedembodiment, two strips of intumescent material 226 a, 226 b areencapsulated by the extruded material. The weatherseal of FIGS. 5A and5B allows for two planes of the closure to be sealed by the intumescentmaterial, when activated. Specifically, when the seal is applied to theclosure, the first intumescent strip 226 a is arranged along the jambsurface of the closure and the second intumescent strip 226 b isarranged along the closure slab. The bulb 240 is not limited to beinghollow and can be made of various materials. The seal 210 could have anyof the other features shown in the foregoing embodiments, including aweakened portion proximate the intumescent material. In an alternativeembodiment, the weatherseal 210 could include only one intumescentmaterial.

Another extruded weatherseal 310 is shown in FIG. 6. This seal 310 hasintumescent material 326 encapsulated by the extruded material, andspaced from flexible fins 314 by a hollow bulb 340. Again, thisweatherseal 310 could include a weakened portion proximate theintumescent material 326, or the extruded material could merely melt inexcessive heat. As in the first embodiment, the flexible fins 314 can beinserted into a kerf to secure the seal 310 relative to the closure.

The extruded weather seals 210, 310 can be formed by extruding aroundthe intumescent material. It has been discovered that the intumescentmaterial may be extruded at a high enough speed such that the materialdoes not intumesce during extrusion when temporarily subjected is themolten extrudate. Specifically, the inventors have fabricated anextruded weatherseal by extruding TPE about an intumescent materialstrip. Other extrudable materials, including, but not limited to, TPEcould alternatively be used such as PVC, urethanes, TPV, styrenicthermoplastic elastomers and EVA. The rate of extrusion could also bevaried, depending on the materials used, to ensure that the materialdoes not intumesce appreciably or at all.

In one example, testing has demonstrated the capability to slip coat theintumescent strip using a extrusion die, by passing the intumescentstrip through an extrusion die at a rate of about 75 feet per minute orgreater, in order to keep the intumescent strip from intumescing. Theextruder barrel and die heats are set in a range of about 350 degreesFahrenheit to about 450 degrees Fahrenheit, depending on the materialbeing used for the slip coat. Testing has also demonstrated the abilityto cross head the extrusion die, so that different components of theweatherseal can be reliably manufactured with different durometermaterials, such as a ridged leg with flexible fins, and a flexible orrigid slip coat. In various embodiments, the slip coat can have athickness in a range of about 0.010 inches to about 0.040 inches or,preferably, about 0.020 inches to about 0.030 inches.

Thus, the present invention provides a unitary weatherseal withintegrated intumescent material. The weatherseal is easily installed bythe user and has proven sealing properties. The invention can be appliedto other shapes and configurations, as well. Moreover, although the sealmay be designed with fins or the like for insertion into a kerf, theseal could alternatively be affixed to the frame of the enclosure usingother methods, such as an adhesive tape or fasteners disposed along thespine. In these alternative embodiments, the fins need not be included.In all instances, the various embodiments of weatherseals disclosedherein and that are within the level of skill in the art from theteachings herein may be considered drop-in replacements fornon-intumescent weatherseals. Accordingly, whether for new applicationsor retrofit applications, the substitution of the weatherseals accordingto the invention provide all of the advantages of intumescentweatherseals, without the need to reconfigure or redesign thefenestration or complicate the weatherseal installation. Further, thereis no need to provide and install, in combination, both a weathersealand a separate intumescent material seal in side-by-side or stackedrelation in the same location. Weatherseals according to the inventionhave relatively large sealing surfaces, making them ideal forconventional sealing against passage of rain, drafts, and cold smokeconditions, as well as for emergency sealing against fire and hot gasand smoke conditions.

The foregoing embodiments of the invention are representativeembodiments, and are provided only for illustrative purposes. Theembodiments are not intended to limit the scope of the invention.Variations and modifications are apparent from a reading of thepreceding description and are included within the scope of theinvention. The invention is intended to be limited only by the scope ofthe accompanying claims.

The invention claimed is:
 1. An intumescent weatherseal adapted to beinstalled in a door or window opening comprising: a spine having firstand second ends, the first end adapted for mounting the weatherseal inthe opening; a resilient foam core attached to the spine, proximate thesecond end of the spine; an intumescent material arranged at an outersurface of the foam core; and a liner enclosing the resilient foam coreand the intumescent material, wherein the intumescent material isdisposed between the foam core and the liner, and at least a portion ofthe intumescent material is in contact with the liner.
 2. Theweatherseal of claim 1, wherein the resilient foam core, the intumescentmaterial, and the liner comprise a substantially V-shaped flexible seal.3. The weatherseal of claim 2, the V-shape comprising a support legproximate the spine and a sealing leg depending angularly from thesupport leg.
 4. The weatherseal of claim 3, wherein the intumescentmaterial is disposed in at least one of the support leg and the sealingleg.
 5. The weatherseal of claim 4, wherein the intumescent material isformed in the support leg and extends along a side of the support legdisposed outside the V-shape.
 6. The weatherseal according to claim 1,wherein the foam core comprises one of an open and closed cell foam. 7.The weatherseal of claim 6, wherein the foam comprises polyetherurethane.
 8. The weatherseal according to claim 1, further comprisingone or more flexible fins depending from the spine.
 9. The weathersealof claim 1, wherein the liner comprises a weakened portion proximate theintumescent material.
 10. The weatherseal of claim 9, wherein theweakened portion is one of a series of perforations, a material having amelting point substantially at or less than an activation temperature ofthe intumescent material, and a flexible material.
 11. The weathersealof claim 1, wherein at least a portion of the weatherseal comprisescoloring coding.
 12. The weatherseal of claim 11, wherein an exposedportion of the spine comprises color coding.
 13. The weatherseal ofclaim 11, wherein the color coding comprises a red coloring.